Wall Pack Light Fixture

ABSTRACT

A lighting fixture includes a first housing portion and a second housing portion. The first housing portion includes a base and a wall extending outwardly from substantially the perimeter of the base. A top portion of the wall includes one or more hinges extending outwardly therefrom. The second housing portion includes a front panel and a side panel extending outwardly from substantially the perimeter of the front panel. A top portion of the front panel includes at least one slot. The second housing is coupled to the first housing in an open position when the hinge is inserted into the slot and the front panel is disposed elevationally above the base. The second housing is coupled to the first housing in an operational position when the hinge is inserted into the slot and the front panel covers the base.

RELATED APPLICATIONS

The present application is a continuation of and claims priority under35 U.S.C. §120 to U.S. Non-Provisional patent application Ser. No.14/330,728, titled “Wall Pack Light Fixture,” and filed Jul. 14, 2014,which is a continuation of and claims priority under 35 U.S.C. §120 toU.S. Non-Provisional patent application Ser. No. 13/091,922, titled“Wall Pack Light Fixture,” and filed on Apr. 21, 2011. The entirecontents of each of the above identified related patent applications arehereby incorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to light fixtures. Morespecifically, the present invention relates to wall pack light fixturesthat include a housing formed with two or more components.

BACKGROUND

One particular type of light fixture is known as a wall pack lightfixture. A wall pack light fixture is typically installed to a supportstructure, such as a vertically oriented wall. Several wall pack lightfixtures include housings formed of two or more individual componentscoupled to one another. The individual components of the housing includeat least a mounting portion and a cover coupled to the mounting portion.The wall pack light fixture typically houses one or more light sourcesfor providing illumination to a desired illuminated area.

Installation of the housing of conventional wall pack light fixturesoccurs in at least two separate steps. The mounting portion is firstmounted to the wall and then the cover is later coupled to the mountingportion in a proper position. During this step where the mountingportion is mounted to the wall, the mounting portion is securely mountedto the wall or is screwed into a J-box. One or more electrical wiresthat are located within or adjacent to the support structure are routedinto the mounting portion and electrically coupled to the light source,thereby providing current to the light source. Also during this step,the cover is typically propped in an inconvenient and/or in a costlymanner. In certain instances, the inconvenient manner in which the coveris propped causes the installer to rush through the installation andpossibly make mistakes.

Conventional approaches to propping the cover include the installerholding the cover in one hand, thereby causing the installer to makewiring connections with the other hand. This approach is veryinconvenient to the installer and does not allow the installer to easilymake the connections. Another conventional approach to propping thecover includes placing the cover on the ladder. This approach is notsafe since the cover can fall off of the ladder and be damaged or causeinjury to a person. Alternatively, the placement of the cover caninterfere with the installer's installation of the fixture. Anotherconventional approach to propping the cover includes placing the coveron a safety cable. This approach adds additional time for setting up anddisassembling the safety cable, which therefore adds additional costsfor the installation. Also, the cover can be inadvertently disconnectedfrom the safety cable or can come in the way of the installer during theinstallation process. Another conventional approach to propping thecover includes using captive hinges located along the left or right sideof the wall pack light fixture that allow the cover to rotate open in ahorizontal manner. This approach requires that there be sufficient roomin front of the wall pack light fixture so that the cover can fullyrotate about the captive hinges. Thus, the installer has to leanbackwards to allow the cover to rotate, which can cause the installer tofall off the ladder. Alternatively, the installer has to maintain hisladder a required distance away from the wall pack light fixture so thatwhen he climbs up the ladder, he is not interfering with the rotation ofthe cover. According to this situation, the installer has to leanforward to perform the installation of the fixture because the ladder isnot positioned as close to the fixture as typically desired.

SUMMARY

An exemplary embodiment of the invention includes a housing. The housingcan include a mounting box and a cover box. The mounting box can includea base and a top wall that extends outwardly from the base. The top wallcan include at least one hinge extending outwardly from the top wall.The cover box can include a front panel and a top panel extendingoutwardly from the front panel. The top panel can include at least oneslot formed therein. The cover box can be coupled to the mounting box inan operational position and in an open position. The operationalposition can occur when the hinge is inserted into the slot and thefront panel covers the base. The open position can occur when the hingeis inserted into the slot and the front panel is disposed elevationallyabove the base.

Another exemplary embodiment of the invention includes a light fixture.The light fixture can include a housing and a light source. The housingcan include a mounting box and a cover box. The mounting box can includea base and a wall extending outwardly from substantially the perimeterof the base. A top portion of the wall can include at least one hingeextending outwardly from the wall. The cover box can include a frontpanel and a side panel extending outwardly from substantially theperimeter of the front panel. A top portion of the side panel caninclude at least one slot formed therein. A bottom portion of the sidepanel can include an opening formed therein. The light source can bedisposed within the housing and can emit light through the opening. Thecover box can be coupled to the mounting box in an operational positionand in an open position. The operational position can occur when thehinge is inserted into the slot and the front panel covers the base. Theopen position can occur when the hinge is inserted into the slot and thefront panel is disposed elevationally above the base.

Another exemplary embodiment of the invention includes a method forinstalling a light fixture. The method can include coupling a mountingbox to a support structure. The mounting box can include a base and awall extending outwardly from substantially the perimeter of the base. Atop portion of the wall can include at least one hinge extendingoutwardly from the wall. The method also can include routing one or moreelectrical wires into the mounting box through an opening formed in themounting box. The method also can include coupling a cover box to themounting box in an open position. The cover box can include a frontpanel and a side panel extending outwardly from substantially theperimeter of the front panel. A top portion of the side panel caninclude at least one slot formed therein. The open position can occurwhen the hinge is inserted into the slot and the front panel is disposedelevationally above the base. The method also can include electricallycoupling the electrical wires to a light source coupled to the coverbox. The method further can include removing the cover box from themounting box. The method also can include recoupling the cover box tothe mounting box in an operational position. The operational positioncan occur when the hinge is inserted into the slot and the front panelcovers the base.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and aspects of the invention are bestunderstood with reference to the following description of certainexemplary embodiments, when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1A is a perspective view of a wall pack light fixture in anoperational position in accordance with an exemplary embodiment of thepresent invention;

FIG. 1B is another perspective view of the wall pack light fixture ofFIG. 1A in accordance with an exemplary embodiment of the presentinvention;

FIG. 1C is a top view of the wall pack light fixture of FIG. 1A inaccordance with an exemplary embodiment of the present invention;

FIG. 1D is a front view of the wall pack light fixture of FIG. 1A inaccordance with an exemplary embodiment of the present invention;

FIG. 2A is a perspective view of a mounting box of the wall pack lightfixture of FIG. 1A mounted to a support structure in accordance with anexemplary embodiment of the present invention;

FIG. 2B is another perspective view of the mounting box of FIG. 2A inaccordance with an exemplary embodiment of the present invention;

FIG. 3A is a perspective view of a cover box of the wall pack lightfixture of FIG. 1A in accordance with an exemplary embodiment of thepresent invention;

FIG. 3B is another perspective view of the cover box of FIG. 3A inaccordance with an exemplary embodiment of the present invention;

FIG. 3C is a rear perspective view of the cover box of FIG. 3A inaccordance with an exemplary embodiment of the present invention;

FIG. 3D is a cross-sectional view of the cover box of FIG. 3A inaccordance with an exemplary embodiment of the present invention;

FIG. 4A is a perspective view of the wall pack light fixture of FIG. 1Ain an open position in accordance with an exemplary embodiment of thepresent invention; and

FIG. 4B is a side view of the wall pack light fixture of FIG. 4A inaccordance with an exemplary embodiment of the present invention.

The drawings illustrate only exemplary embodiments of the invention andare therefore not to be considered limiting of its scope, as theinvention may admit to other equally effective embodiments.

BRIEF DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present invention is directed to wall pack light fixtures. Althoughthe exemplary embodiment described below is of a wall pack light fixtureusing solid state light emitters, e.g., light emitting diodes (“LEDs”)and LED packages, other exemplary embodiments of the invention use otherlight source types, such as compact fluorescent light bulbs, highintensity discharge (“HID”) lamps, and halogen bulbs. The invention isbetter understood by reading the following description of non-limiting,exemplary embodiments with reference to the attached drawings, whereinlike parts of each of the figures are identified by like referencecharacters, and which are briefly described as follows.

FIGS. 1A-1D show several views of a wall pack light fixture 100 in anoperational position 102 in accordance with an exemplary embodiment ofthe present invention. Referring to FIGS. 1A-1D, the wall pack lightfixture 100 includes a mounting box 110, a cover box 140, one or morelight sources 180, and a lens 190. According to certain exemplaryembodiments, the wall pack light fixture 100 also includes a driver 394(FIG. 3C) and/or a reflector 196. In the operational position 102, themounting box 110 is coupled to a support structure 105, such as avertically oriented wall, and the cover box 140 is coupled to themounting box 110.

FIG. 2A is a perspective view of the mounting box 110 of the wall packlight fixture 100 mounted to the support structure 105 in accordancewith an exemplary embodiment of the present invention. FIG. 2B is afront view of the mounting box 110 in accordance with an exemplaryembodiment of the present invention. Referring to FIGS. 1A-2B, themounting box 110 is substantially rectangular or square shaped, but isshaped in a substantially different geometric or non-geometric shape inother exemplary embodiments. The mounting box 110 is fabricated usingdie cast aluminum, but is fabricated using other suitable materialsincluding, but not limited to, plastic, other metals, or metal alloys inother exemplary embodiments. The mounting box 110 includes a base 211, afirst sidewall 218, a second sidewall 224, a top wall 230, and a bottomwall 240.

The base 211 is substantially rectangular or square shaped, but isshaped in a substantially different geometric or non-geometric shape inother exemplary embodiments. The base 211 includes a first edge 212, asecond edge 213, a third edge 214, and a fourth edge 215. The first edge212 is positioned opposite the second edge 213 and the third edge 214 ispositioned opposite the fourth edge 215. The base 211 also includes oneor more openings 216 allowing a fastening device (not shown), such as ascrew or a nail, to be inserted therethrough to couple the mounting box110 to the support structure 105. The openings 216 are formed during theformation of the base 211. Alternatively, the openings 216 are formedafter the base 211 has been fabricated, such as by cutting portions ofthe base to form the openings 216. One or more of the openings 216 areshaped into various geometric and/or non-geometric shapes including, butnot limited to, elongated slots, circles, or a combination of elongatedslots having a circle at one end of the elongated slot. The base 211also includes an aperture 217 positioned substantially at or near thecenter of the base 211. Alternatively, the aperture 217 is not includedin the base 211 or is formed elsewhere within the base 211. The aperture217 allows for electrical wires (not shown) to be passed through fromwithin the support structure 105 into the mounting box 110, therebyallowing the electrical wires to be electrically coupled to the lightsources 180, which is described in further detail below.

The first sidewall 218 extends outwardly from the first edge 212 in asubstantially perpendicular manner. Alternatively, the first sidewall218 extends outwardly from the first edge 212 in an angular manner. Thefirst sidewall 218 includes a proximal end 219 positioned along thefirst edge 212 and a distal end 220. The distal end 220 forms a planarsurface 221 that is substantially parallel to the base 211. According tocertain exemplary embodiments, a first conduit opening (not shown) isformed within the first sidewall 218. The first conduit opening allowsfor electrical wires (not shown) to be passed through from within oradjacent to the support structure 105 into the mounting box 110, therebyallowing the electrical wires to be electrically coupled to the lightsources 180, which is described in further detail below. In certainexemplary embodiments where the first conduit opening is not utilized, afirst conduit cap 222 is coupled to the first sidewall 218 and coversthe first conduit opening. The first conduit cap 222 is rotatablycoupled to the first sidewall 218 within the first conduit opening insome exemplary embodiments. However, the first conduit cap 222 iscoupled to the first sidewall 218 within the first conduit openingaccording to other suitable methods, such as snap-fitting, in otherexemplary embodiments.

The second sidewall 224 extends outwardly from the second edge 213 in asubstantially perpendicular manner. Alternatively, the second sidewall224 extends outwardly from the second edge 213 in an angular manner. Thesecond sidewall 224 includes a proximal end 225 positioned along thesecond edge 213 and a distal end 226. The distal end 226 forms a planarsurface 227 that is substantially parallel to the base 211. According tosome exemplary embodiments, the second sidewall's planar surface 227lies substantially within the same plane as the first sidewall's planarsurface 221. According to certain exemplary embodiments, a secondconduit opening 228 is formed within the second sidewall 224. The secondconduit opening 228 allows for electrical wires (not shown) to be passedthrough from within or adjacent to the support structure 105 into themounting box 110, thereby allowing the electrical wires to beelectrically coupled to the light sources 180, which is described infurther detail below. In certain exemplary embodiments where the secondconduit opening 228 is not utilized, a second conduit cap 129 is coupledto the second sidewall 224 and covers the second conduit opening 228.The second conduit cap 129 is rotatably coupled to the second sidewall224 within the second conduit opening 228 in some exemplary embodiments.However, the second conduit cap 129 is coupled to the second sidewall224 within the second conduit opening 228 according to other suitablemethods, such as snap-fitting, in other exemplary embodiments.

The top wall 230 extends outwardly from the third edge 214 in asubstantially perpendicular manner and also extends from one end of thefirst sidewall 218 to one end of the second sidewall 224. Alternatively,the top wall 230 extends outwardly from the third edge 214 in an angularmanner instead of in a perpendicular manner. The top wall 230 includes aproximal end 231 positioned along the third edge 214 and a distal end232. The distal end 232 forms a planar surface 233 that is substantiallyparallel to the base 211. According to some exemplary embodiments, thetop wall's planar surface 233 lies substantially within the same planeas the first sidewall's planar surface 221 and the second sidewall'splanar surface 227. According to some exemplary embodiments, the topwall's planar surface 233 forms a continuous surface with the firstsidewall's planar surface 221 and the second sidewall's planar surface227. According to certain exemplary embodiments, a top conduit opening(not shown) is formed within the top wall 230. The top conduit openingallows for electrical wires (not shown) to be passed through from withinor adjacent to the support structure 105 into the mounting box 110,thereby allowing the electrical wires to be electrically coupled to thelight sources 180, which is described in further detail below. Incertain exemplary embodiments where the top conduit opening is notutilized, a top conduit cap 234 is coupled to the top wall 230 andcovers the top conduit opening. The top conduit cap 234 is rotatablycoupled to the top wall 230 within the top conduit opening in someexemplary embodiments. However, the top conduit cap 234 is coupled tothe top wall 230 within the top conduit opening according to othersuitable methods, such as snap-fitting, in other exemplary embodiments.

The top wall 230 also includes one or more hinges 235 positionedadjacent the distal end 232. There are two hinges 235 illustrated in oneof the exemplary embodiments; however, greater or fewer hinges 235 arepositioned on the top wall 230 in other exemplary embodiments. Eachhinge 235 extends substantially perpendicularly outward from the topwall 230 in a direction substantially away from the bottom wall 240.Each hinge 235 includes a lower portion 236 and a top portion 237. Thelower portion 236 extends substantially perpendicularly outward from thetop wall 230 in a direction substantially away from the bottom wall 240.The lower portion 236 also extends in a direction parallel to the distalend 232. In certain exemplary embodiments, the lower portion 236 extendsto about an outer edge 239 of the top wall's planar surface 233. The topportion 237 extends continuously from the end of the lower portion 236in a direction away from the top wall 230 and in a direction away fromthe top wall's planar surface 233. Thus, the top portion 237 has acurvature shape. According to some exemplary embodiments, the hinge 235also includes a locator 238 that extends substantially perpendicularlyoutward from the top wall 230 in a direction substantially away from thebottom wall 240 and substantially perpendicularly away from the lowerportion 236. In some exemplary embodiments, the locator 238 extends fromthe lower portion 236 in a direction away from the top wall's planarsurface 233. However, in certain exemplary embodiments, the locator 238extends from the lower portion 236 in a direction towards the top wall'splanar surface 233. This hinge 235 is formed as a single component incertain exemplary embodiments. In alternative exemplary embodiments, thehinge 235 is formed using several components that are subsequentlycoupled together. Although one configuration and/or shape of the hinge235 is described and illustrated, other configurations and/or shapes ofthe hinge 235 can be used in other exemplary embodiments.

The bottom wall 240 extends outwardly from the fourth edge 215 in asubstantially perpendicular manner and also extends from an opposing endof the first sidewall 218 to another end of the second sidewall 224.Alternatively, the bottom wall 240 extends outwardly from the fourthedge 215 in an angular manner instead of in a perpendicular manner. Thebottom wall 240 includes a proximal end 241 positioned along the fourthedge 215 and a distal end 242. The distal end 242 forms a planar surface243 that is substantially parallel to the base 211. According to someexemplary embodiments, the bottom wall's planar surface 243 liessubstantially within the same plane as the first sidewall's planarsurface 221, the second sidewall's planar surface 227, and the topwall's planar surface 233. According to some exemplary embodiments, thebottom wall's planar surface 243 forms a continuous surface with thefirst sidewall's planar surface 221, the second sidewall's planarsurface 227, and the top wall's planar surface 233. According to certainexemplary embodiments, an opening 244 is formed within the bottom wall'splanar surface 243 and extends through at least a portion of the bottomwall 240. The opening 244 is configured to receive a screw 109 or otherknown fastening device.

According to some exemplary embodiments, the bottom wall 240 alsoincludes a protrusion 250. Protrusion 250 extends outwardly from thebottom wall 240 in a direction away from the top wall 230. A portion ofthe protrusion 250 forms a planar surface 251 adjacent to the bottomwall's planar surface 243. According to some exemplary embodiments, theprotrusion's planar surface 251 lies substantially in the same plane asthe bottom wall's planar surface 243. Similar to the opening 244 formedin the bottom wall's planar surface 243, a second opening 252 is formedin the protrusion's planar surface 251. The second opening 252 isconfigured to receive a screw (not shown), similar to screw 109, orother known fastening device. This second opening is utilized whencoupling a larger sized cover box than cover box 140.

According to some exemplary embodiments, the mounting box 110 is moldedas a single component. Alternatively, the mounting box 110 is formedfrom several components that are subsequently coupled to one another. Insome exemplary embodiments, a gasket 280 is positioned on each of thefirst sidewall's planar surface 221, the second sidewall's planarsurface 227, the top wall's planar surface 233, and the bottom wall'splanar surface 243 prior to coupling the cover box 140 to the mountingbox 110 in the operational position 102. The gasket 280 forms a sealbetween the mounting box 110 and the cover box 140 to prevent theingress of moisture and other contaminants from a surroundingenvironment, thereby allowing the wall pack light fixture 100 to beoperable in an outside environment. The gasket 280 is fabricated using arubber material or any other known suitable material capable of beingcompressed and providing a seal.

FIGS. 3A-3D show several views of the cover box 140 in accordance withan exemplary embodiment of the present invention. Referring to FIGS.1A-1D and 3A-3D, the cover box 140 has a substantially rectangular orsquare shaped front profile, but is shaped in a substantially differentgeometric or non-geometric shape in other exemplary embodiments. Thecover box 140 is fabricated using die cast aluminum, but is fabricatedusing other suitable materials including, but not limited to, othermetals or metal alloys that are capable of conducting heat in otherexemplary embodiments. The cover box 140 is fabricated as a singlecomponent, but can be fabricated in multiple components and thereafterassembled together. The cover box 140 includes a front panel 310, afirst side panel 330, a second side panel 335, a top panel 340, and abottom panel 345, which collectively form a cavity region 320 therein.

The front panel 310 has a substantially rectangular or square shapedfront profile, but is shaped in a substantially different geometric ornon-geometric shape in other exemplary embodiments. The front panel 310includes a first edge 321, a second edge 322, a third edge 323, and afourth edge 324. The first edge 321 is positioned opposite the secondedge 322 and the third edge 323 is positioned opposite the fourth edge324. The first and second edges 321, 322 are curved, while the third andfourth edges 323, 324 are substantially straight. However, inalternative exemplary embodiments, the one or more of the edges 321,322, 323, and 324 are different.

The front panel 310 includes a front surface 312 and a rear surface 314.The front surface 312 is viewable to an observer once the cover box 140is coupled to the mounting box 110 in the operational position 102. Thefront surface 312 is formed having a non-planar, curvature shape.However, in other exemplary embodiments, the front surface 312 issubstantially planar. The front panel 310 includes openings 316 formedtherein that extend toward the rear surface 314, but does not extendthrough the rear surface 314. According to certain exemplaryembodiments, the openings 316 are formed during the fabrication processof the cover box 140. Each opening 316 is substantially rectangularlyshaped along the surface of the front surface 312 and is linearlyaligned with an adjacent opening 316; however, one or more openings 316are shaped differently and/or not linearly aligned with an adjacentopening 316 in other exemplary embodiments. Each opening 316 extendssubstantially longitudinally and extends in a direction substantiallyparallel to the first and second edges 321, 322. However, one or moreopenings 316 are oriented in a different manner in other exemplaryembodiments.

A fin 317 is formed between adjacent openings 316 which allows for theremoval of at least a portion of any accumulated heat that is generatedby either the driver 394 and/or the light sources 180. Each fin 317includes a first end 318 and a second end 319, which are both positionedalong the front surface 312. Each fin 317 forms at least one edge of acorresponding opening 316. Also, each fin 317 extends inwardly towardsthe cavity region 320 from about the front surface 312 of the frontpanel 310, through the rear surface 314 of the front panel 310, and intothe cavity region 320 of the cover box 140, which is adjacent to atleast the rear surface 314. The portion of the fins 317 that extendsfrom about the front surface 312 of the front panel 310 to the rearsurface 314 of the front panel 310 is referred to as external fins 398.The portion of the fins 317 that extends from the rear surface 314 ofthe front panel 310 and into the cavity region 320 of the cover box 140is referred to as internal fins 399. As the external fins 398 extendfrom about the front surface 312 of the front panel 310 towards the rearsurface 314, the thickness of the external fins 398 increases.Alternatively, the thickness of one or more external fins 398 decreases,remains the same, increases, or is a combination of the aforementionedas the external fins 398 extend from about the front surface 312 of thefront panel 310 toward the rear surface 314. Additionally, the distancethat each external fin 398 extends from the front surface 312 towardsthe rear surface 314 is smaller at the first end 318 and the second end319 of each external fin 398 and progressively increases alongintermediate portions of the external fin 398 moving away from each ofthe first end 318 and the second end 319. In some exemplary embodiments,the distance that each external fin 398 extends from the front surface312 towards the rear surface 314 is the greatest when a portion of theexternal fin 398 extends to a horizontally intermediate edge 315 thatextends horizontally along the rear surface 314. This horizontallyintermediate edge 315 is located near the lower portion of the rearsurface 314 according to some exemplary embodiments. Alternatively, oneor more external fins 398 travel from about the front surface 312 of thefront panel 310 towards the rear surface 314 in a different manner thanpreviously described. The shape and orientation of the external fins 398promote air flow along the external fins 398 by creating a “chimneyeffect,” which forces air in at the bottom of the external fins 398,causes the air to rise along the external fins 398, and forces the airout and away from the external fins 398 near the top of the externalfins 398.

The front panel 310 includes an aperture 370 for receiving the screw109, or other suitable fastening device, for coupling the cover box 140to the mounting box 110. The aperture 370 is positioned between adjacentfins 317 and is aligned with the opening 244 (FIG. 2B) of the mountingbox 110 when the cover box 140 is coupled to the mounting box 110 in theoperational position 102. The aperture 370 is accessible from the frontsurface 112 of the front panel 110 and extends into the cavity region320. According to one exemplary embodiment, the aperture 370 ispositioned to extend substantially perpendicular through thehorizontally intermediate edge 315 of the rear surface 314. However, theaperture 370 is positioned elsewhere on the front panel 310 in otherexemplary embodiments, so long as the aperture is aligned with theopening 244 (FIG. 2B) when the cover box 140 is coupled to the mountingbox 110 in the operational position 102.

The front panel 310 also includes one or more screw mounts 375 thatextend from the rear surface 314 of the front panel 310 towards thecavity region 320. The screw mounts 375 are positioned between adjacentinternal fins 399 and/or adjacent one or more internal fins 399.According to some exemplary embodiments, one or more screw mounts 375are in contact with at least one of the internal fins 399. The screwmount 375 is circular in shape according to some exemplary embodimentsand is capable of receiving a screw 376 for mounting the driver 396 tothe front panel 310. Once mounted, the driver 396 is in thermal contactwith one or more of the internal fins 399.

The first side panel 330 extends outwardly from the first edge 321 in asubstantially perpendicular manner from the front panel 310 such that atleast a portion of the first side panel 330 faces at least a portion ofone of the fins 317. Alternatively, the first side panel 330 extendsoutwardly from the first edge 321 in an angular manner. Similarly, thesecond side panel 335 extends outwardly from the second edge 322 in asubstantially perpendicular manner from the front panel 310 such that atleast a portion of the second side panel 335 faces at least a portion ofone of the fins 317. Alternatively, the second side panel 335 extendsoutwardly from the second edge 322 in an angular manner.

The top panel 340 extends outwardly from the rear surface 314 adjacentthe third edge 323 in a substantially perpendicular manner and alsoextends from an upper portion of the first side panel 330 to an upperportion of the second side panel 335. Thus, the top panel 340 is notcoupled to any edges of the front panel 310, the first side panel 330,and the second side panel 335. However, in alternative exemplaryembodiments, at least one edge of the top panel 340 is coupled to atleast one edge of the front panel 310, the first side panel 330, and thesecond side panel 335. Alternatively, the top panel 340 extendsoutwardly from the rear surface 314 in an angular manner instead of in aperpendicular manner. The top panel 340 includes two slots 342 formedtherein, each slot 342 shaped to receive a corresponding hinge 235. Incertain exemplary embodiments, each slot 342 is an elongated shape andextends in a direction parallel to the third edge 323. In some exemplaryembodiments, each slot 342 includes one or more notches 343 extendingsubstantially perpendicular to the elongated portion of the slot 342.The notch 343 is shaped to receive the locator 238 of the hinge 235,thereby properly positioning the cover box 140 to the mounting box 110.In certain exemplary embodiments, fewer slots 342 are formed in the toppanel 340 than corresponding hinges 235 on the top wall 230. Forexample, a single elongated slot extending substantially parallel to thethird edge 323 is formed in the top panel 340. This single elongatedslot is shaped to receive both hinges 235 coupled to the top wall 230therein.

The bottom panel 345 extends outwardly from the rear surface 314 at thefourth edge 324 in a substantially perpendicular manner and also extendsfrom a lower edge of the first side panel 330 to a lower edge of thesecond side panel 335. However, in alternative exemplary embodiments, atleast one edge of the bottom panel 345 is coupled to at least one lowerportion of the front panel 310, the first side panel 330, and the secondside panel 335. Alternatively, the bottom panel 345 extends outwardlyfrom the rear surface 314 in an angular manner instead of in aperpendicular manner. An opening 346 is formed at the surface of thebottom panel 345 and extends toward the top panel 340 thereby forming acompartment 347. The compartment 347 is separated from the cavity region320 by a compartment wall 348. The compartment wall 348 includes ainternal surface 349 facing the opening 346 and an exterior surface 350.In certain exemplary embodiments, one or more fins 351 extendsubstantially vertically from along a portion of the exterior surface350 of the compartment wall 348 to the rear surface 314 of the frontpanel 310. In certain exemplary embodiments, the fins 351 extend to aportion of the rear surface 314 that is positioned at and between thehorizontally intermediate edge 315 of the rear surface 314 and thefourth edge 324 of the front panel 310. These fins 351 assist inremoving heat generated from the light sources 180 and allow the heat tobe transferred to the rear surface 314 and then the fins 317.

In certain exemplary embodiments, the cover box 140 also includes asealing panel 360 extending into the cavity region 320 from the rearsurface 314 of the front panel 310. The sealing panel 360 is sized andshaped to be similar to the collective shape of the bottom wall's planarsurface 243 (FIG. 2B), the first sidewall's planar surface 221 (FIG.2B), the second sidewall's planar surface 227 (FIG. 2B), and the topwall's planar surface 233 (FIG. 2B) of the mounting box 110. Thus, oncethe cover box 140 is coupled to the mounting box 110 in the operationalposition 102, the sealing panel 360 is pressed into the gasket 280 thatis disposed atop each of the bottom wall's planar surface 243 (FIG. 2B),the first sidewall's planar surface 221 (FIG. 2B), the second sidewall'splanar surface 227 (FIG. 2B), and the top wall's planar surface 233(FIG. 2B) of the mounting box 110, thereby forming a seal.

The driver 394 is electrically communicable with the one or more lightsources 180 using a cable (not shown) and is also electrically coupledto the electrical wires routed into the mounting box 110 from oradjacently from the support structure 105. The driver 394 provides powerto the one or more light sources 180 and also controls the intensityand/or color of the light sources 180. For example, the driver 394 iscapable of dimming the light sources 180 if desired. The driver 394produces heat which is removed from within the wall pack light fixture100 to an external area outside of the wall pack light fixture via thefins 317. As previously mentioned, the driver 394 is coupled to one ormore fins 317 within the cavity region 320. However, in other exemplaryembodiments, the driver 394 is coupled to the mounting box 110 withoutdeparting from the scope and spirit of the exemplary embodiment.

According to this exemplary embodiment, the light source 180 includesone or more LED die packages, or LEDs, coupled to a substrate (notshown). The substrate is mounted to the internal surface 349 of thecompartment wall 348 and is oriented so that the LED die packages 180are emitting light towards the opening 346. However, in other exemplaryembodiments, the substrate and hence the light source 180 is coupled tothe mounting box 110 without departing from the scope and spirit of theexemplary embodiment. The substrate includes one or more sheets ofceramic, metal, laminate, circuit board, Mylar®, or another material.Each LED die package 180, or LED, includes a chip of semi-conductivematerial that is treated to create a positive-negative (“p-n”) junction.When the LED die packages 180, or LEDs, are electrically coupled to apower source, such as the driver 394, current flows from the positiveside to the negative side of each junction, causing charge carriers torelease energy in the form of incoherent light.

The wavelength or color of the emitted light depends on the materialsused to make the LED die packages 180, or LEDs. For example, a blue orultraviolet LED typically includes gallium nitride (“GaN”) or indiumgallium nitride (“InGaN”), a red LED typically includes aluminum galliumarsenide (“AlGaAs”), and a green LED typically includes aluminum galliumphosphide (“AlGaP”). Each of the LEDs in the LED die package 180 canproduce the same or a distinct color of light. For example, in certainexemplary embodiments, the LED die package 180 includes one or morewhite LEDs and one or more non-white LEDs, such as red, yellow, amber,or blue LEDs, for adjusting the color temperature output of the lightemitted from the fixture 100. A yellow or multi-chromatic phosphor maycoat or otherwise be used in a blue or ultraviolet LED to create blueand red-shifted light that essentially matches blackbody radiation. Theemitted light approximates or emulates “white,” incandescent light to ahuman observer. In certain exemplary embodiments, the emitted lightincludes substantially white light that seems slightly blue, green, red,yellow, orange, or some other color or tint. In certain exemplaryembodiments, the light emitted from the LED die packages 180, or LEDs,has a color temperature between 2500 and 5000 degrees Kelvin.

In certain exemplary embodiments, an optically transmissive or clearmaterial (not shown) encapsulates at least a portion of each LED diepackage 180, or LED. This encapsulating material provides environmentalprotection while transmitting light from the LED die package 180, orLED. In certain exemplary embodiments, the encapsulating materialincludes a conformal coating, a silicone gel, a cured/curable polymer,an adhesive, or some other material known to a person of ordinary skillin the art having the benefit of the present disclosure. In certainexemplary embodiments, phosphors are coated onto or dispersed in theencapsulating material for creating white light. In certain exemplaryembodiments, the white light has a color temperature between 2500 and5000 degrees Kelvin.

In certain exemplary embodiments, the LED die packages 180, or LEDs,includes one or more arrays of LED die packages 180, or LEDs, that arecollectively configured to produce a lumen output from 1 lumen to 5000lumens. The LED die packages 180, or LEDs, are attached to the substrateby one or more solder joints, plugs, epoxy or bonding lines, and/orother means for mounting an electrical/optical device on a surface. Thesubstrate is electrically connected to support circuitry (not shown)and/or the driver 394 for supplying electrical power and control to theLED die packages 180, or LEDs. For example, one or more wires (notshown) couple opposite ends of the substrate to the driver 394, therebycompleting a circuit between the driver 394, the substrate, and the LEDdie packages 180, or LEDs.

The reflector 196 is fabricated from a plastic material according tosome exemplary embodiments, while in others, the reflector 196 is formedfrom other suitable materials, such as aluminum, any other reflectivetype material, or any material capable of having its surface be madereflective. In some exemplary embodiments, the plastic material isinjection molded and vacuum metalized to form the reflector 196. Thereflector 196 is made from a single component or is made from severalcomponents that are subsequently coupled together. The reflector 196includes one or more openings 197 that is disposed around each of thelight sources 180 once inserted within the compartment 347. Thereflector 196 also includes an interior surface 198 that faces theopening 346 once inserted within the compartment 347. The interiorsurface 198 is finished to be reflective to light using methods known topeople having ordinary skill in the art. For example, the interiorsurface 198 can be polished, coated with a reflective material,fabricated using a reflective material, or made reflective using othermethods known to people having ordinary skill in the art.

The lens 190 is disposed over the light sources 180 to collectivelyencapsulate the light sources 180. The lens 190 is coupled to the bottompanel 345 over the perimeter of the opening 346 using VHB® adhesivetape, silicone adhesive, or any other known adhesive. In alternativeexemplary embodiments, the lens 190 is coupled to the bottom panel 345over the perimeter of the opening 346 using brackets (not shown) and/orother fasteners that are known to people having ordinary skill in theart, such as a slot formed adjacently around the perimeter of theopening 346 wherein the edges of the lens 190 are inserted therein. Inone exemplary embodiment, the lens 190 is fabricated from an opticallytransmissive material or clear material including, but not limited to,plastic, glass, silicone, or other material known to people havingordinary skill in the art. According to certain exemplary embodiments,the lens 190 encapsulates at least some of the light sources 180individually. The lens 190 provides environmental protection whileallowing light emitted by the light sources 180 to pass therethroughtoward the desired illumination area. In certain other exemplaryembodiments, the lens 190 focuses light toward the desired illuminationarea and creates a desired light distribution. In certain exemplaryembodiments, the lens 190 diffuses the light emitted from the lightsources 180. In yet another exemplary embodiment, the lens 190 createsan insulation between the light sources 180 and human contact. The lens190 has a substantially planar shape; however, the lens 190 is formedinto other geometric or non-geometric shapes in other exemplaryembodiments.

FIG. 4A is a perspective view of the wall pack light fixture 100 in anopen position 402 in accordance with an exemplary embodiment of thepresent invention. FIG. 4B is a side view of the wall pack light fixture100 in the open position 402 in accordance with an exemplary embodimentof the present invention. Referring to FIGS. 4A-4B and 1A-1D, theinstallation of the wall pack light fixture 100 is described. Althoughthe description provided below is presented in a certain order, it isrealized that the order of the installation steps can be varied.

Referring to FIGS. 4A-4B, the electrical wires (not shown) locatedwithin the support structure 105 or located adjacent to the supportstructure 105 are made accessible. These electrical wires are routedinto the mounting box 110 through at least one of the aperture 217 orthe conduit openings 228 positioned within any of the first sidewall218, the second sidewall 224, and the top wall 230. The mounting box 110is oriented against the support structure 105 with the top wall 230being elevationally higher than the bottom wall 240. According to someexemplary embodiments, the top wall 230 is leveled substantiallyhorizontally. Once oriented, the mounting box 110 is coupled to thesupport structure 105 by inserting screws or other fastening devicesthrough one or more openings 216. Alternatively, the mounting box 110 iscoupled to the support structure 105 using other known fasteningdevices, such as nails or clips.

The cover box 140 is coupled to the mounting box 110 in the openposition 402 by placing the top panel 340 of the cover box 140 adjacentto the top wall 240 of the mounting box 110 and inserting each of thehinges 234 through the corresponding slots 342. In the open position402, the bottom panel 345 of the cover box 140 is positionedelevationally higher than the top panel 340 and the front panel 310 isadjacent the support structure 105. According to certain exemplaryembodiments, the cover box 140 is resting against the support structure105 because the center of gravity of the cover box 140 is closer towardsthe support structure 105 while in the open position 402. The shape ofthe hinge 234 prevents the cover box 140 from being inadvertentlyremoved from the mounting box 110. Specifically, the curvature shape ofthe top portion 237 (FIG. 2A) prevents the cover box 140 from beingaccidentally removed off of the mounting box 110. The cover box 140 isvertically lifted off of the mounting box 110 to remove the cover box140 from the mounting box 110. While in the open position 402, theinstaller is able to use two hands and make the proper wiringconnections between the driver 394 and the electrical wires. Uponcompleting the wiring, the installer has the ability to verify that theinstallation has been performed properly.

Once the wiring has been completed, the installer removes the cover box140 off of the hinges 235, rotates the cover box 180 degrees, andrecouples the cover box 140 to the mounting box 110 in the operationalposition 102 (FIGS. 1A-1D). Referring to FIGS. 1A-1D, when recouplingthe cover box 140 to the mounting box 110 in the operational position102, the hinges 235 are inserted through the corresponding slots 342from the cavity region 320 (FIG. 3C). The locator 238 is aligned to beinserted through a corresponding notch 343, which properly aligns thecover box 140 to the mounting box 110.

Once the cover box 140 is positioned in the operational position 102,the screw 109 is tightened to firmly press the gasket 280 (FIG. 2B) toeach of the first sidewall's planar surface 221 (FIG. 2B), the secondsidewall's planar surface 227 (FIG. 2B), the top wall's planar surface233 (FIG. 2B), and the bottom wall's planar surface 243 (FIG. 2B),thereby creating a seal.

Although each exemplary embodiment has been described in detail, it isto be construed that any features and modifications that are applicableto one embodiment are also applicable to the other embodiments.Furthermore, although the invention has been described with reference tospecific embodiments, these descriptions are not meant to be construedin a limiting sense. Various modifications of the disclosed embodiments,as well as alternative embodiments of the invention will become apparentto persons of ordinary skill in the art upon reference to thedescription of the exemplary embodiments. It should be appreciated bythose of ordinary skill in the art that the conception and the specificembodiments disclosed may be readily utilized as a basis for modifyingor designing other structures or methods for carrying out the samepurposes of the invention. It should also be realized by those ofordinary skill in the art that such equivalent constructions do notdepart from the spirit and scope of the invention as set forth in theappended claims. It is therefore, contemplated that the claims willcover any such modifications or embodiments that fall within the scopeof the invention.

What is claimed is:
 1. A light fixture comprising: a housing comprising:a mounting box forming a first cavity; and a cover box that fastens tothe mounting box, the cover box forming a second cavity, the cover boxcomprising: a first side that faces the mounting box when the cover boxis fastened to the mounting box; a first plurality of walls defining anouter perimeter of the cover box; a sealing surface within the secondcavity and within the outer perimeter of the cover box, the sealingsurface engaging the mounting box when the cover box is fastened to themounting box; a second side that faces away from the mounting box whenthe cover box is fastened to the mounting box; a lower portion of thecover box; at least one light emitting diode (LED) oriented to emitlight from the lower portion; and a driver that is mounted to the coverbox and electrically connected to the at least one light emitting diode.2. The light fixture of claim 1, wherein the mounting box comprises asecond plurality of sidewalls on which a gasket sits, the sealingsurface engaging the gasket on the second plurality of sidewalls of themounting box when the cover box is fastened to the mounting box.
 3. Thelight fixture of claim 1, wherein the cover box comprises heat sinkfins.
 4. The light fixture of claim 1, wherein the lower portion of thecover box comprises heat sink fins.
 5. The light fixture of claim 1,further comprising a reflector mounted in the lower portion.
 6. Thelight fixture of claim 5, wherein the LED is disposed at an aperture ofthe reflector.
 7. The light fixture of claim 1, further comprising aplurality of projections on the mounting box, the plurality ofprojections configured to support the cover box during installation ofthe light fixture.
 8. The light fixture of claim 1, wherein when thecover box is fastened to the mounting box, the driver is disposed in anenclosed volume defined by the cover box and the mounting box.
 9. Alight fixture comprising: a housing comprising: a mounting box having afirst length, the mounting box forming a first cavity; and a cover boxthat fastens to the mounting box, the cover box having a second lengththat is longer than the first length, the cover box comprising: a secondcavity that faces the mounting box when the cover box is fastened to themounting box; a sealing surface within the second cavity, the sealingsurface engaging the mounting box when the cover box is fastened to themounting box; a lower portion; and at least one light emitting diode(LED) oriented to emit light from the lower portion; and a driver thatis mounted within the housing and electrically connected to the at leastone light emitting diode.
 10. The light fixture of claim 9, wherein themounting box comprises a plurality of sidewalls on which a gasket sits,the sealing surface engaging the gasket on the plurality of sidewalls ofthe mounting box when the cover box is fastened to the mounting box. 11.The light fixture of claim 9, wherein the cover box comprises heat sinkfins.
 12. The light fixture of claim 9, wherein the lower portion of thecover box comprises heat sink fins.
 13. The light fixture of claim 9,further comprising a reflector mounted in the lower portion.
 14. Thelight fixture of claim 13, wherein the LED is disposed at an aperture ofthe reflector.
 15. The light fixture of claim 9, further comprising aplurality of projections on the mounting box, the plurality ofprojections configured to support the cover box during installation ofthe light fixture.
 16. The light fixture of claim 9, wherein when thecover box is fastened to the mounting box, the driver is disposed in anenclosed volume defined by the cover box and the mounting box.
 17. Alight fixture comprising: a housing comprising: a mounting box forming afirst cavity; and a cover box that fastens to the mounting box, thecover box comprising: a second cavity that faces the mounting box whenthe cover box is fastened to the mounting box; a sealing surface withinthe second cavity, the sealing surface engaging the mounting box whenthe cover box is fastened to the mounting box; and a lower portioncomprising at least one light emitting diode (LED) oriented to emitlight from the cover box; and a driver that is mounted within thehousing and electrically connected to the at least one light emittingdiode.
 18. The light fixture of claim 17, wherein the cover boxcomprises heat sink fins.
 19. The light fixture of claim 17, wherein thelower portion comprises at least one reflector.
 20. The light fixture ofclaim 17, further comprising a plurality of projections on the mountingbox, the plurality of projections configured to support the cover boxduring installation of the light fixture.